Nanoindenter

ABSTRACT

A new type of indenter is described. This device combines certain sensing and structural elements of atomic force microscopy with a module designed for the use of indentation probes, conventional diamond and otherwise, as well as unconventional designs, to produce high resolution and otherwise superior indentation measurements.

CROSS-REFERENCE

This application is a continuation application of U.S. Ser. No. 12/729,339 filed Mar. 23, 2010, now U.S. Pat. No. 8,196,458 issued Jun. 12, 2012, which is a continuation application of U.S. Ser. No. 11/724,067 filed Mar. 13, 2007, now U.S. Pat. No. 7,685,869 issued Mar. 30, 2010, which claims priority from provisional 60/782,072, filed Mar. 13, 2006, the entire contents of the disclosure of which is herewith incorporated by reference.

BACKGROUND OF THE INVENTION

An AFM is a device used to produce images of surface topography (and other sample characteristics) based on information obtained from rastering a sharp probe on the end of a cantilever relative to the surface of the sample. Deflections of the cantilever, or changes in its oscillation, which are detected while rastering correspond to topographical (or other) features of the sample. Deflections or changes in oscillation are typically detected by an optical lever arrangement whereby a light beam is directed onto a cantilever in the same reference frame as the optical lever. The beam reflected from the cantilever is made to illuminate a position sensitive detector (PSD). As the deflection or oscillation of the cantilever changes, the position of the reflected spot on the PSD changes, causing a change in the output from the PSD. Changes in the deflection or oscillation of the cantilever are typically made to trigger a change in the vertical position of the cantilever base relative to the sample, in order to maintain the deflection or oscillation at a constant pre-set value. It is this feedback that generates an AFM image. AFMs can be operated in a number of different imaging modes, including contact mode where the tip of the cantilever is in constant contact with the sample surface, and oscillatory modes where the tip makes no contact or only intermittent contact with the surface.

Actuators are commonly used in AFMs, for example to raster the probe relative to the sample surface or to change the position of the cantilever base relative to the sample surface. The purpose of actuators is to provide relative movement between the probe and the sample. For different purposes and different results, it may be useful to actuate the sample, or the tip or some combination of both. Sensors are also commonly used in AFMs. They are used to detect movement of various components of the AFM, including movement created by actuators. For the purposes of the specification, unless otherwise specified, the term “actuator” refers to a broad array of devices that convert input signals into physical motion, including piezo activated flexures, piezo tubes, piezo stacks, blocks, bimorphs, unimorphs, linear motors, electrostrictive actuators, electrostatic motors, capacitive motors, voice coil actuators and magnetostrictive actuators, and the term “position sensor” or “sensor” refers to a device that converts a displacement, velocity or acceleration into an electrical signal, including capacitive sensors, inductive sensors (including eddy current sensors), differential transformers (such as described in co-pending applications US20020175677A1 and US20040075428A1, Linear Variable Differential Transformers for High Precision Position Measurements, and US20040056653A1, Linear Variable Differential Transformer with Digital Electronics, which are hereby incorporated by reference in their entirety), variable inductance, optical interferometry, optical deflection detectors (including those referred to above as a PSD and those described in co-pending applications US20030209060A1 and US20040079142A1, Apparatus and Method for Isolating and Measuring Movement in Metrology Apparatus, which are hereby incorporated by reference in their entirety), strain gages, piezo sensors, magnetostrictive and electrostrictive sensors.

SUMMARY OF THE INVENTION

We have developed a nanoindenter that produces very accurate, quantitative characterization for a wide spectrum of materials. The new nanoindenter may be implemented on an atomic force microscope (AFM) platform, but unlike indentation that might be effected with an AFM cantilever, the invention drives the indenting tip perpendicularly into the sample. Displacement and force are measured with optimized LVDT sensors and an optical lever, respectively, the same devices that eliminate inaccuracies (e.g. non linearity) present in measurements made with AFMs, and this greatly increases sensitivity and resolution in comparison to commercial indenters. This highly quantitative tool, incorporating high end AFM capabilities breaks new ground in characterization of a great diversity of materials including thin films, coatings, polymers, etc. As noted, the nanoindenter may be implemented on an AFM platform and when integrated with the native metrology abilities of the Molecular Force Probe-3D AFM of Asylum Research Corporation, it enables the user to perform quantitative indentation measurements and to make quantitative statements regarding the indenter tip shape and indentation volumes and profiles, all with the same instrument set-up.

In addition to an AFM platform, the new nanoindenter may be implemented on other cantilever-based instruments. Cantilever-based instruments include such instruments as AFMs, molecular force probe instruments (1D or 3D), high-resolution profilometers and chemical or biological sensing probes. For the sake of convenience, the specification focuses on AFMs. However, it should be understood that problems addressed and solutions presented by the present invention are also applicable to other instruments with nanoscale motion and metrology applications.

The systems and techniques described herein provide a novel device for nanoscale metrology that permits quantitative measurements of indentation and related parameters better than is presently possible with commercially available tools.

Specifics of the invention will be described in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is the new indenter module attached to an existing AFM.

FIG. 2 is the new indenter module placed in the MFP-3D AFM of Asylum Research Corporation.

FIG. 3 is the new indenter module prior to assembly.

FIG. 4 is the flexure mounted on the circular plate/retaining ring of the new indenter module.

FIG. 5 is the flexure of the new indenter module.

FIG. 6 is a cross sectional view of the mechanical converter system of the new indenter module.

FIG. 7 is a perspective view from the top of the mechanical converter system of the new indenter module.

FIG. 8 is another new indenter module prior to assembly.

FIG. 9 is a bottom-side plan view of the indenter module of FIG. 8 after assembly.

FIG. 10 is a plan view of the planar leaf springs of the assembled flexure of indenter module of FIG. 8.

FIG. 10 through FIG. 15 are plan views of planar leaf springs of other assembled flexures for other indenter modules.

FIG. 16 is another new indenter module prior to assembly.

FIG. 17 is a bottom-side plan view of the indenter module of FIG. 16 after assembly.

FIG. 18 is a plan view of the planar leaf springs of the assembled flexure of indenter module of FIG. 16.

FIG. 19 is a perspective view of an optical lever detection system designed to substitute for the mechanical converter system depicted in FIG. 6.

DETAILED DESCRIPTION

One preferred embodiment of the current invention is depicted in FIG. 1, showing a cross-sectional view of a module embodying the invention which is installed in an AFM in place of the cantilever holder. Panels (A) and (B) of FIG. 1 each show the module rotated 90 degrees about the vertical central shaft of the module which culminates in the indenter probe 303 positioned over a stage 307 on which a sample could be attached. This embodiment of the invention allows it to take direct advantage of some or all of the existing sensors and structures of an AFM.

FIG. 2 shows the module embodying the invention 12 installed in a Molecular Force Probe-3D AFM from Asylum Research Corporation (only the head 13 of the MFP-3D is shown). In the configuration depicted in FIG. 2, the indenter module 12 is removable and makes use of the actuators, sensors and optics of the head 13, In particular, the z-piezo 14 of the MFP-3D is used to actuate the indenter probe 303 and the z-LVDT sensor 17 of the MFP-3D may be used to measure the displacement of the indenter probe 303. The position sensitive detector 16 of the MFP-3D is used to measure the motion of the flexure controlling the displacement of the indenter probe 303. Using data from these sensors, it is possible to quantify the displacement and force acting between the indenter probe 303 and a sample (not shown).

Another useful feature of the indenter module 12 being installed in the MFP-3D head 13 is that the module can use certain optical features of the head for providing an optical view of the indenter probe 303 and the sample. The top-view objective 18 and steering mirror 19 of the MFP-3D head 13 work with the prism of the indenter module 12 to provide an optical view of both the indenter probe 303 and the sample (not shown), as well as to illuminate both. This is of great utility for aligning the indenter probe 303 with particular structures on the sample.

The indenter can similarly be installed in AFMs manufactured by other companies and, with modifications, in yet other AFMs. The MFP-3D of Asylum Research Corporation is particularly amenable to conversion to an indenter because the actuators, sensors and optics located in its head are appropriate and convenient for indenter purposes. The same is true of other AFMs, or could be made to be true with modifications.

Except where clearly stated otherwise, the remainder of this detailed discussion of the current invention is directed at an indenter module that might be installed in any AFM, not just the MFP-3D of Asylum Research Corporation, as well as to a stand-alone indenter that is not a component of an AFM.

FIG. 3 shows a perspective view of the module embodying the invention prior to assembly. The indenter probe 303 is mounted on a removable chuck 304. The chuck 304 allows the user to employ a variety of standard and custom indenter probes and to change easily from one probe to another. As is well-known to those versed in the art, these probes are formed of different materials, including diamond, tungsten, silicon nitride and others. The chuck 304 is attached to a monolithic three-dimensional leaf spring flexure 305 which is designed to constrain the motion of the indenter probe 303 to the z-axis only, that is, perpendicular to the sample. Precluding motion in the other axes is a major contributor to the results available with the invention. The flexure 305 is rigidly attached to the bottom of a circular plate with a retaining ring 310 on its top which is designed to mount into an AFM in place of the cantilever holder. This permits the actuator (not shown), which in an AFM would be used to change the position of the cantilever base in response to changes in the deflection or oscillation of the cantilever, to be used to actuate the circular plate/retaining ring 310 and through it to actuate the flexure 305, the chuck 304 and the indenter probe 303. Measurement of this actuation may be improved through the use of a sensor (not shown) to measure the displacement.

As shown in FIG. 3, the module embodying the invention may also include a prism 306 to permit an oblique view of the sample (not shown) on the sample holder 307, the indenter probe 303 and their interface where the AFM in which the module is mounted includes an optical view system. The module may also include a dust cover 308 to protect the flexure 305, the circular plate/retaining ring 310 and the prism 306 from external contamination and prevent damage from handling. The dust cover 308 may also provide mechanical hard stops (not shown) to prevent the flexure 305 from being overextended. A shake piezo (not shown) to oscillate the flexure 305, and thus the chuck 304 and the indenter probe 303, when the measurement is to be made in an AC mode could be added at the point where collar 320 screws into the flexure 305 or alternatively could be attached to the circular plate/retaining ring 310.

FIG. 4 is a perspective view of the flexure 305 mounted on the circular plate/retaining ring 310, with the chuck 304, the indenter probe 303 and the prism 306 shown assembled. The flexure 305 is a monolithic, and three-dimensional leaf spring with three supporting ends 403, a flexing portion, a central shaft 404, which is free to move in response to the application of force. The supporting ends 403 are each rigidly attached to the circular plate/retaining ring 310. The chuck 304 is rigidly attached to one end of the flexing portion, the central shaft 404, and the indenter probe 303 is attached to the chuck 304, facing the sample to be indented.

FIG. 5 is a second perspective view of the flexure 305, absent the other items shown in FIG. 4. Such flexures are fabricated using metals and machining methods, including electronic discharge machining, well-known to those versed in the art.

FIG. 6 shows a cross-sectional view of the central shaft 404 of the flexure 305, with the chuck 304 attached to one end (and the indenter probe 303 attached to the chuck 304) and a collar 320 attached to the other end which is inserted through a hole in the center of the circular plate/retaining ring 310 and gives access to the central shaft 404 from within the AFM to enable a mechanical converter assembly. The purpose of the mechanical converter assembly is to convert the zaxis linear motion of the central shaft 404, chuck 304 and indenter probe 303 into an angular change that an optical lever detector system, which in an AFM would be used to detect changes in the deflection or oscillation of the cantilever, can measure. When the indenter module is mounted into an AFM in place of the cantilever holder and the circular plate/retaining ring 310 is actuated, thereby displacing flexure 305, chuck 304 and indenter probe 303 toward the sample, one end of a second flexure, planar flexure 314, which is rigidly attached to the circular plate/retaining ring 310 is also displaced. At the same time, the other end of planar flexure 314, which on one side is linked though a ball bearing mechanism 318 to the central shaft 404 and on the other side is attached to a wedge-shaped mirror mount 315, and is free to flex is also displaced, with the displacement following that of the central shaft 404. This displacement of the flexing end of the planar flexure 314 tilts the mirror mount 315, and mirror 309 attached to the mount, and thereby steers the light beam of an optical lever detection system (not shown) from one place on the position sensitive detector of the system to another thereby providing a measure of the displacement of the indenter probe 303. A small permanent magnet 324 keeps the mirror mount 315 and planar flexure 314 in contact with the ball bearing surface 318.

The design of the mechanical converter assembly allows the motion of the indenter tip 303 to be measured in much the same manner as cantilever tip deflection or oscillation are measured in a conventional AFM. Together with the use of the z-axis actuator previously discussed, this allows the indenter module to be easily swapped with the cantilever holder of an AFM, resulting in a unique, useful and versatile instrument that allows the user to bring the functionality of an AFM to bear on indenting.

FIG. 7 shows a perspective view from above of the mechanical converter assembly discussed in the preceding paragraph. The two ends of a planar flexure 314, the support end 316 rigidly attached to the circular plate/retaining ring 310, and therefore displaced in tandem with actuation of the circular plate/retaining ring 310, and a flexing end 317 linked though a ball bearing mechanism 318 to the central shaft 404 and also attached to the mirror mount 315, and therefore displaced in tandem with the central shaft, are displayed with greater clarity. FIG. 7 also shows the hard stops 311 built into the mechanical converter assembly to prevent the flexure 305 from being overextended or damaged by normal handling.

The planar flexure 314 has a very high compliance when compared to the indenting flexure 305, that is, the spring constant of the planar flexure 314 is very low compared to the spring constant of the indenting flexure 305.

It will be observed that the indenting flexure 305 plays a major role in the performance of the preferred embodiment of the current invention which has just been discussed. A second preferred embodiment, employing a different indenting flexure but, like the first preferred embodiment, designed to be installed in an AFM in place of the cantilever holder in order to make use of the actuators, sensors and optics of the AFM is depicted in FIG. 8, a perspective view of the module embodying the invention prior to assembly.

Unlike the monolithic three-dimensional leaf spring flexure 305 of the first preferred embodiment, the flexure of FIG. 8 is an assembled flexure. Like that flexure, however, the assembled flexure of FIG. 8 is designed to constrain the motion of the indenter probe 303 to the z-axis only, that is, perpendicular to the sample. The flexing portion of the assembled flexure of FIG. 8 is provided by the central shaft of two circular, planar leaf springs 506 and 507, which are firmly constrained at the support end, that is the perimeter, by interleaved clamps, 503, 504 and 505. The assembly of planar leaf springs 506 and 507 and interleaved clamps, 503, 504 and 505 is rigidly attached to the circular plate/retaining ring 310. The central shaft of the planar leaf springs 506 and 507 is composed of spindles 508 and 509. The upper end of spindle 508 screws into the lower end of spindle 509, through holes 514, clamping planar leaf spring 506 against the stop at the lower end of spindle 509. The stop at the upper end of spindle 509 is fastened to planar leaf spring 507 and the portion of the spindle above the stop extends through a hole in the center of the circular plate/retaining ring 310 and gives access to the central shaft from within the AFM to enable the mechanical converter assembly discussed above in connection with the first preferred embodiment to function.

As with the first preferred embodiment, the central shaft of the assembled flexure of FIG. 8 ends with the chuck 304, rigidly attached to the lower end of spindle 508, and the indenter probe 303 attached to the chuck 304, facing the sample to be indented. The assembled flexure, the chuck 304 and the indenter probe 303 are actuated by actuating the circular plate/retaining ring 310 with the actuator (not shown) which in the AFM would be used to change the position of the cantilever base in response to changes in the deflection or oscillation of the cantilever.

FIG. 9 is a bottom-side plan view of the flexure of FIG. 8 after assembly. FIG. 10 is a plan view of the planar leaf springs 506 and 507 of the flexure of FIG. 8, showing different parts of the springs. Such springs are fabricated using metals, including beryllium copper, and machining methods well-known to those versed in the art.

Other preferred embodiments of the current invention, also designed to be installed in an AFM in place of the cantilever holder in order to make use of the actuators, sensors and optics of the AFM, but employing different indenting flexures than indenting flexure 305 of the first preferred embodiment or the assembled flexure of FIG. 8, form part of the invention. FIG. 10 shows springs 604, holes 605 and central shaft 606. FIG. 11 shows other springs 607, holes 608 and central shaft 609. FIG. 12 shows other springs 610, holes 611 and central shaft 612. FIG. 13 shows the springs 805, central connection 807 and holes 806. FIG. 14 shows springs 808, central receiving shaft 807 and holes 806. FIG. 15 shows the shaft 807, springs 809 and holes 806. Altogether, FIG. 11 through FIG. 15 are plan views of the planar leaf springs of such other preferred embodiments. Each of them consists of a flexing portion in the center of the spring, support ends at the perimeter and connections from the flexing portions to the support ends of variously shaped beams. In addition to the circles and other depicted shapes of these planar leaf springs, any polygon would in general produce similar results when paired with appropriate connections. Holes 806 and the shaft 807 are also shown in FIGS. 16 and 18 Another embodiment showing springs 810 is also shown in FIG. 18.

An additional preferred embodiment, again employing a different indenting flexure but, like the other preferred embodiments disclosed above, designed to be installed in an AFM in place of the cantilever holder in order to make use of the actuators, sensors and optics of the AFM is depicted in FIG. 16, a perspective view of the module embodying the invention prior to assembly. Like the flexure of FIG. 8, the flexure of FIG. 16 is an assembled flexure and is designed to constrain the motion of the corresponding probe 703 (which is also an optical element) to the zaxis only, that is perpendicular to the sample.

The components of the assembled flexure of FIG. 16 are similar to those of the assembled flexure of FIG. 8: two planar leaf springs 707 and 708 separated by clamps 705 and 706. However, the assembled flexure of FIG. 16 does not have a third clamp separating the upper planar leaf spring 708 from the plate 709 which facilitates installation of the assembly in an AFM in place of the cantilever holder. Instead, planar leaf springs 708 is rigidly attached directly to the plate 709.

The central shaft of the planar leaf springs 707 and 708 of the assembled flexure of FIG. 16 also differs from the central shaft of the assembled flexure of FIG. 8. The central shaft of the planar leaf springs 707 and 708 consists of just a chuck 704, and the probe 703 attached to the chuck 704, facing the sample to be indented. The upper end of the chuck 704 extends through a hole in the center of the plate 709 and gives access to the central shaft from within the AFM to enable the mechanical converter assembly discussed above in connection with the first preferred embodiment to function.

The probe 703 of the assembled flexure of FIG. 16 is a new device not currently known in the art and as such is significantly different from the indenter probe 303 of the assembled flexure of FIG. 8. Probe 703 has both a different function than indenter probe 303 and a different construction. Probe 703 has a dual function: it is both an optical element and an indenting probe. As an optical element, probe 703 acts as a lens allowing the optical viewer system of the AFM head in which assembled flexure of FIG. 16 is installed with a direct optical view of the sample to be indented. As an indenting probe, probe 703 is a rigid element that applies force and indents the sample as with traditional indenter probes, such as 303. With this dual function comes a requirement for a different construction. A probe like probe 703 must be fabricated from a material which is both very hard and transparent to light. Suitable materials include diamond and sapphire.

Probe 703 has many advantages over other indenter transducers or indenting probes. These include making available a true top optical view of the sample to be indented, allowing for accurate positioning of indentations and having a combination of low mass and high resonant frequency, which allows unprecedented resolution in the measurement of mechanical behavior of materials through both static and dynamic material testing methods.

FIG. 17 is a bottom-side plan view of the flexure of FIG. 16 after assembly. FIG. 18 is a plan view of the planar leaf springs of the flexure of FIG. 16. Such springs are fabricated using metals, including beryllium copper, and machining methods well-known to those versed in the art.

FIG. 19 shows an optical lever detection system designed to free the modules embodying the current invention from the use of the mechanical converter assembly described above in order to access the optical lever detection system of an AFM. A mirror 1901 is attached to the collar 320 which is rigidly attached to central shaft 404, chuck 304 and indenter probe 303 of the flexure of the first preferred embodiment of the invention. Mirror 1901 deflects an incident light beam coming into the optical lever detection system and as this mirror moves relative to the indenter probe 303, a PSD of the optical lever detection system measures the displacement. An additional lens 1902 may be placed above mirror 1901 to increase sensitivity and facilitate calibration of the optical lever detection system.

The described embodiments of the invention are only considered to be preferred and illustrative of the inventive concept. The scope of the invention is not to be restricted to such embodiments. Various and numerous other arrangements may be devised by one skilled in the art without departing from the spirit and scope of the invention. 

The invention claimed is:
 1. An assembly, comprising: a measuring instrument which includes a connection to a measuring part, an actuator for said measuring part, and sensors for measuring displacement and force of said measuring part, where said measuring part is adapted to connect to an optical lever that has a lever that moves at a non-perpendicular angle relative to a sample being measured; and an indenter portion, including an indenter probe, said indenter portion being movable to move perpendicularly relative to the sample being measured, and connects to said connection and uses the same actuator and sensors as said measuring part, wherein said indenter portion includes a three-dimensional flexure through which the indenter probe is moved by said actuator in a Z axis direction, which is a direction perpendicular to a plane of the flexure and perpendicular to the sample being measured.
 2. An assembly as in claim 1, wherein said measuring instrument is an atomic force microscope.
 3. An assembly, comprising: a measuring instrument which includes a connection to a cantilever, an actuator for said cantilever, and sensors for measuring displacement and force of said cantilever; and an indenter portion, including an indenter probe, said indenter portion being movable to move perpendicularly relative to a sample being measured, wherein said indenter probe uses the same actuator and sensors as said instrument, and wherein said indenter portion includes a three-dimensional flexure through which the indenter probe is moved by said actuator in a Z axis direction, which is a direction perpendicular to a plane of the flexure and perpendicular to the sample, wherein said assembly further comprising a cover which constrains movement of said flexure beyond a specified amount.
 4. An assembly as in claim 3 wherein said cover includes hard stops that prevent extending the flexure in said Z axis direction by more than a specified amount.
 5. An assembly, comprising: a measuring instrument which includes a connection to a cantilever, an actuator for said cantilever, and sensors for measuring displacement and force of said cantilever; and an indenter portion, including an indenter probe, said indenter portion being movable to move perpendicularly relative to a sample being measured, wherein said indenter probe uses the same actuator and sensors as said instrument, and wherein said indenter portion includes a three-dimensional flexure through which the indenter probe is moved by said actuator in a Z axis direction, which is a direction perpendicular to a plane of the flexure and perpendicular to the sample, wherein said flexure has first, second and third portions which constrain the flexure against movement in directions other than said Z axis direction and a flexing portion at a center portion thereof.
 6. An assembly as in claim 5, wherein said flexure is a three-dimensional leaf spring having three supporting portions at outer edges thereof.
 7. An assembly, comprising: a measuring instrument which includes a connection to a cantilever, an actuator for said cantilever, and sensors for measuring displacement and force of said cantilever; and an indenter portion, including an indenter probe, said indenter portion being movable to move perpendicularly relative to a sample being measured, wherein said indenter probe uses the same actuator and sensors as said instrument, and wherein said indenter portion includes a three-dimensional flexure through which the indenter probe is moved by said actuator in a Z axis direction, which is a direction perpendicular to a plane of the flexure and perpendicular to the sample, wherein said assembly further comprising a structure that converts linear motion of the indenter probe into angular motion of a type that is monitored by sensors of the cantilever. 